Method of manufacturing electromagnetic devices using kinetic spray

ABSTRACT

A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

BACKGROUND OF INVENTION

[0001] The present invention relates to a method of manufacturingelectric machines including motors and generators using kinetic sprayingmetal forming. More specifically, the present invention is directlyrelated to a method of manufacturing both conductive metallizations, aswell as permanent and soft magnets by applying highly-defined,high-velocity sprays of conductors and magnetic materials in powder formto an appropriate carrier without the need for additional molding,shaping, sintering or tooling steps.

DESCRIPTION OF THE RELATED ARTS

[0002] “Electric machines” in the broadest sense, are fabricated fromspecialized arrangements of conductive coils, magnetic materials,supporting structures, and ancillary components such as fasteners,wires, and other conductors.

[0003] Most “permanent” magnets and some “soft” magnets are producedthrough a molding and sintering operation from an admixture of magneticmaterials and appropriate binders in an initially powdered form, whereinthe final shape of the particular magnet is dictated by the mold toolingused. Additionally, “permanent” magnets must be magnetized by exposingthe magnet to sufficiently high magnetic fields so as to introduce astrong, semi-permanent magnetic alignment of individual magnetic dipolesand larger physical domains. “Soft” magnetic materials, usuallypredicated on iron and several of its alloys, are often fabricated fromsintered powders or laminated sheets, produced such that the intrinsicmagnetic moment for the material is not permanent, but rather isdetermined by the magnitude of the applied field. Coils madepredominantly from copper wire are used both to generate magnetic fieldsand electromagnetic torque in the airgap, with the ultimate goal togenerate motion, as in an electric motor, or to generate electric poweras in a generator or alternator. Electric machines, which may be eithergenerators or motors, are thus assembled from specific geometric arraysof coils, magnetic materials and supporting structures or carriers.Assembly processes for electric machines involve attachment of magnets,laminations and coils to housings designed to receive the magnet. Whenmultiple magnets are assembled, it becomes difficult to precisely alignand attach each magnet to the article or housing. A process thateliminates the molding, hardening and assembly steps greatly simplifiesthe construction process and reduces the cost and complexity of theresultant article. Moreover, by supplying the constituent materials ofthe particular electric machine as “coatings” in contrast to separatethree-dimensional structures, it is possible to realize new anddifferent electric machines, fabricated by an unconventional processonto heretofore unused carriers or platforms.

[0004] It is possible to thermal spray magnetic materials onto a carrieras described in U.S. Pat. No. 5,391,403 ('403). This thermal sprayprocess has been used where relatively weak magnetic fields aresufficient such as for use in a sensor. The method described in the '403patent is capable of producing very thin magnetic coatings between100-200 μm in thickness. This coating was made from magnetic oxides ofiron, cobalt and nickel. The intense heat from the thermal spray processcauses the base metals to oxidize and produce oxides. The oxides producemuch weaker magnetic fields than the base metals from which theyoriginate. They lack the capacity to produce sufficiently strong fieldsrequired for motors and generators. The present invention is directed toa method of producing magnets from base metals that are capable ofproducing strong magnetic fields.

[0005] U.S. Pat. No. 4,897,283, teaches a method of producing alignedpermanent magnets by a high temperature plasma thermal spray ofsamarium-cobalt. Auxiliary heat is applied before, during and after thethermal spray to produce the magnet. Because the deposition is conductedin an environmentally-controlled chamber, oxidation of the metallicalloy is expected to be minimal. Masking is optionally used to producefine deposition features, as is well-known in the thermal-spray art. Thetemperature needed to produce the plasma spray degrades the magneticproperties of the resulting article.

[0006] Thermal spray has the advantage of being capable of rapidlyproducing a layer of bulk material atop a carrier, but the heat neededto create the molten metal droplets can alter the magnetic properties ofthe sprayed material. Another family of thermal spray technologies thatdoes not use high temperatures for producing molten droplets iscollectively known as kinetic spraying. One kinetic spray techniquepredominantly used to date has been that of cold gas-dynamic spraying or“cold-spray”. The technique described in U.S. Pat. No. 5,302,414incorporated herein by reference, ('414) uses a nozzle whoseacceleration and focusing properties are determined by gas dynamics andgeometry to produce a jet of solid or semi-solid particles that impingeonto a deformable substrate material, typically metal. The particleshave a size range of approximately 1-50 micrometers. The particles areintroduced under pressure into a supersonic gas stream created throughuse of a converging-diverging (deLaval) nozzle. The particles, onceaccelerated to near supersonic velocities, impact on a collectingsubstrate where they form a thick deposit, by a process believed to besimilar to explosive compaction or mechanical plating. The coating maybe applied for a number of purposes such as corrosion or wearresistance. The '414 patent, states that the application method may beused for electrically or magnetically conducting coatings. However, the'414 patent does not provide examples of electrically or magneticallyconductive coatings. The methods described all produce very thin (<400μm) coatings. These coatings are generally too thin to be of use asmagnets such as those typically found in electric machines. The presentinvention is directed to the application of bulk material to producemagnets capable of creating magnetic fields useful in motors, generatorsand similar devices.

[0007] The invention described herein utilizes the “cold spray” processto produce electric machine elements as “coatings” or deposits on anappropriate substrate or carrier. While the '414 patent discloseselectrical and magnetic materials, it does not provide for a methodologyfor permanent magnet deposits, composite magnets, deposition conditions,properties of soft magnetic materials, or suggested geometries forplanarized or ‘coating-based’ electric machines.

SUMMARY OF INVENTION

[0008] The present invention is directed to a method of manufacturingmagnets using a kinetic spray process where the magnetic material is notexposed to high temperatures. This reduces the formation of unwantedoxides and enables the precise build-up of material atop a carrier intothe final desired shape of the magnet. The process utilizes a high-speedkinetic spray propelling a fine metal powder to a target carrier. Themetal powder has a ductile component. The mixture adheres to thecarrier, generally by a mechanical attachment or metallurgical bond. Theductile component serves as the bonding site for subsequent layers ofkinetic spray. The ductile material bonds to the ductile material of theprevious layers. The kinetic spray process or “cold” gas-dynamicspraying enables the deposition of soft magnetic materials with improvedmagnetic properties compared to those produced by high-temperaturethermal spraying based on arcs, plasmas or flames. Additionally, theinvention provides for the formation of planar electrical coils usingthe same technology, such that entire classes of electric machines canbe fabricated using a single spray technology. It will be apparent tothose skilled in the art that in addition to cold-spray deposition,other kinetic spray processes may also be used to produce the lowtemperature, highly-focused deposition such as electrically pulsedplasmas as shown in U.S. Pat. No. 6,001,426, issued Dec. 14, 1999,tribo-acceleration as shown in U.S. Pat. No. 5,795,626, issued Aug. 18,1998, and rail gun plasma acceleration.

BRIEF DESCRIPTION OF DRAWINGS

[0009]FIG. 1 is a diagram of a kinetic cold-spray apparatus that may beused in the preparation of permanent magnets.

[0010]FIG. 2 is a cross-sectional view of hard and soft magneticmaterials applied atop a carrier by cold spraying.

[0011]FIG. 3 is a perspective view of a cold spraying device producing acomplex article.

[0012]FIG. 4 is a perspective view of an article produced by cold spray.

[0013]FIG. 5 is an electric machine made using a soft magnetic carrierto direct the magnetic flux from the permanent magnets through a planarcoil.

DETAILED DESCRIPTION

[0014] The present invention will be described through a series ofdrawings, which illustrate the manufacture of a permanent magnet motor.Other items such as generators, solenoids, actuators and sensors may bemanufactured using the same or similar technique and equipment and areincluded within the invention described herein. The following elementsare a word list of the items described in the drawings and arereproduced to aid in understanding the invention:

[0015]10 cold-spray system

[0016]12 powder feeder

[0017]14 high pressure gas inlet

[0018]16 heater

[0019]18 powder feed tube

[0020]20 enclosure

[0021]22 supersonic nozzle

[0022]24 carrier

[0023]26 bulk material

[0024]28 permanent magnet material

[0025]30 soft magnetic binder material

[0026]32 coil

[0027]34 electrical contact

[0028]36 permanent magnet array

[0029]38 planar coil

[0030]40 motor

[0031]42 support

[0032]44 core

[0033]46 insulator

[0034]48 armature core

[0035]50 magnetic flux

[0036] The invention is a manufacturing method for producing permanentmagnets. The permanent magnets that are the subject of this inventionhave a sufficient magnetic strength to be used in motors and generatorsand are generally referred to a ‘strong magnets’. They are distinguishedfrom ‘weak magnets’ that may be used for sensors and memory storagedevices. Preferably, the magnets are produced in the final desired shapewithout additional hardening or shaping steps. The magnets are formed inlayers directly atop a carrier. Preferably, the carrier is the housing,spindle or other device which utilizes the magnet. The invention will bedescribed as a method of making a magnet that will be used in anelectric motor. Other devices that utilize magnets may be made using thesame equipment, material and techniques as are taught herein such asgenerators, alternators, solenoids, actuators or sensors.

[0037] The equipment used for the manufacture of permanent magnets mayalso be used to create electrical traces, electrical coils and wiring.In this fashion, complete electric machines may be fabricated using acold-spray gun, or similar kinetic deposition processes, by alternatelyproducing the permanent magnet components and then the electrical wiringand coils as will be more completely described.

[0038] The kinetic spray process utilizes a cold-spray system 10. Thesystem 10 includes a powder feeder 12. The powder feeder 12 supplies thepowder materials for kinetic spraying. A high pressure gas 14 propelsthe powder. A heater 16 heats the gas to a temperature much less thenthe melting point of the powder. The powder is directed through a powderfeed tube 18 to the high pressure chamber of a supersonic nozzle 22. Thenozzle 22 propels the powder particles at a carrier 24. The particlesare deposited atop the carrier 24 as a bulk build-up of material 26.

[0039] Illustrated in FIG. 2 is a schematized cross-sectional view ofthe metallurgical microstructure of a magnet produced by the cold-sprayprocess. The carrier 24 may be either a non-magnetic or soft magneticmaterial. Aluminum was found to be a good carrier material because it isnot ferromagnetic and provides a ductile striking surface that enablesthe powdered metal to adhere to the aluminum surface. Aluminum does not,however, provide a low reluctance flux return path needed in highenergy-density motor/generator applications. Iron would provide apreferred substrate in these applications. The bulk material 26 is anadmixture of the powders that are sprayed atop the carrier 24. The bulkmaterial 26 preferably includes a permanent magnet material 28 and asoft magnetic binder material 30. The selection of the cold-spraymaterials includes both magnetic and conductive materials as describedbelow. The magnetic composite 26 utilizes a ductile, soft phase such ahigh-purity iron as a binder to effectively provide both a mechanicalinterlocking of second phase magnetic particles, as well as ametallurgical bond at the atomic level in some instances (e.g. when theinterleaving particle structures are not interrupted by porosity,contamination or non-adhering oxide phases. In general, the precise typeof interparticle bonding will be a function of the material typesemployed, their degree of purity, and the conditions under which thecompact is formed.

[0040] Materials

[0041] Magnetic Binder and ‘Soft Magnet’ Materials.

[0042] Iron is the principal ingredient of “soft” magnetic materialsthat effectively act as a conduit for controlling direction, strength,and storage of magnetic fields. Desirable physical properties are highinternal purities and controlled interfaces in bulk aggregates or piecesto minimize core losses that occur as magnetization is propagatedthrough the material. In such devices as transformer cores, this isachieved through use of insulated lamination layers of sheet electricalsteel. In compacted irons or powder-metallurgy materials, this iseffected on a smaller scale through use of soft-iron powders withpolymeric or lubricant coatings and metal surfaces with developed oxidelayers. Cold spraying of relatively pure iron such as Ancorsteel™ 1000produced by the Hoeganaes Corporation, results in a soft magneticmaterial with a density of approximately 7.46 g/cm³ compared to adensity of 7.86 g/cm³ for bulk pure iron. Saturation magnetization ofcold-sprayed Ancorsteel™ 1000 iron was found to be 1.98 Tesla comparedto 2.15 Tesla for pure iron. Cold-spraying conditions which producedthis material were achieved with pure helium gas at an inlet temperatureof 325-360° C., a gas pressure of 300 psi (2.1 MPa), and iron particlesizes as sieved to −325 mesh (max particle approximately 45micrometers). A thermal spray sample of plain 0.8 carbon steel producedby twin-wire arc process in comparison to the cold spray material showedlower density (6.98 g/cm³) and an appreciably poorer saturationmagnetization of approximately 1.52 Tesla and quasi-static energy lossof 2.1 J/kg/cycle vs. 1.8 J/kg/cycle for the cold-sprayed iron material.These measurements suggest that the cold-spray iron material is greatlysuperior to conventional thermally-sprayed carbon steels when comparingits ability to be magnetized.

[0043] Core losses for cold-sprayed irons, which would dictatehigher-frequency energy losses in applications such as motors andtransformers, may be reduced through compaction of powder materialshaving oxide or polymeric shells, with nominally pure iron in thematerial core. An example of such a material is Somaloy™ 500 of H ö ganä s Corporation. These powders are generally formed into magneticmaterials through warm compaction processes such as those used in powdermetallurgy, however, cold spraying permits development of surfacedeposits of soft magnetic material without use of separate tooling, thuspermitting a variety of structures to be implemented on the appropriatesurface.

[0044] It is possible to reduce the core loss of the sprayed magneticmaterial by providing resistance to eddy current flow between adjacentparticles of binder material. This effect may be achieved by coatingindividual binder particles with an eddy current resistant coating suchas oxide films, organic films and polymeric films.

[0045] Permanent Magnet Materials.

[0046] The second ingredient for a range of electromagnetic devices tobe fabricated by cold-spraying processes is a permanent magnet deposit.Since cold-sprayed iron forms a soft magnet having a saturationmagnetization approaching that of pure iron, it is possible to form apermanent magnet from the pure iron material by exposure to highmagnetic fields. This process is used to produced conventional cast ironmagnets for low-cost, low-performance applications. Alternatively,improved and higher strength permanent magnets in layer or coating formcan be developed through a manner of the cold spray process in which acomposite structure is achieved by spraying an admixture of a permanentmagnet material powder (e.g. neodymium-iron-boron (Fe₁₄Nd₂B), AlNiCo,Sm—Co₅) and suitable ferromagnetic binder such as pure iron, nickel orcobalt, which are known to be sprayable by the cold-gas or relatedprocess. Layers so deposited will be in a non-magnetic condition, so itwill be necessary as a process step to use high magnetic fields toinduce a permanent magnet moment in the resulting structure.

[0047] A composite microstructure may be obtained by cold-spraying anadmixture of permanent magnet material and soft magnetic binder. Suchcomposite microstructures containing hard embedded phases in softductile materials such as high-purity iron or nickel have beendemonstrated for carbides in a nickel-chromium alloy matrix in a paperby McCune, R. C., A. N. Papyrin, J. N. Hall, W. L. Riggs, II and P. H.Zajchowski, “An Exploration of the Cold Gas-Dynamic Spray Method forSeveral Materials Systems,” Advances in Thermal Spray Science andTechnology, Proc. 8th. National Thermal Spray Conference, C. C. Berndtand S. Sampath, Eds., ASM Int'l., 1995 p 1-5, and incorporated herein byreference. The amount of binder phase necessary to develop robustcomposites is approximately 50% by volume and is believed to be afunction of the plasticity of the permanent magnet material; less binderphase being required for more ductile materials. A minimum amount of“ductile phase” required to form a permanent magnet deposit is on theorder of 10-15% by volume of the softer phase. High-purity nickel isimmediately substitutable for iron in these compacts, and it is believedthat cobalt would also be readily usable as a binder at particlevelocities greater than those used for iron or nickel.

[0048] he present invention produces strong magnetic materials have verylow content of oxides; less than 5% by volume. This low oxideconcentration produces strong magnets that better retain a permanentmagnetic dipole alignment and produce stronger magnetic fields.

[0049] Copper.

[0050] The third element of electromagnetic devices is a copper (orother high-conductivity et al) winding. Copper is used for connectionpoints or pads and for making coil elements in both motor and generatorconfigurations. The cold spray copper deposit is developed from highpurity, (preferably <0.25% wt oxygen content) inert gas-atomized copperpowder with an optimum particle size range between 10 and 30micrometers. In the cold-gas spray method, copper is deposited at a gaspressure of 2-2.4 MPa (280-340 psi) using dry nitrogen gas, with gaspreheat conditions of 300-325° C. Nozzles may be configured to providemetal deposits having widths as small as 1 mm. Deposit thickness of asmuch as 3-5 mm are possible for larger metallization widths (e.g. 10cm). Other metals having good electrical conductivity and particleplasticity will be apparent, including silver, gold and aluminum ofpurities greater than 99%. Alloyed or so-called dispersion-strengthenedmetals of comparable electrical conductivity are also candidatematerials for the electrical metallization or coil structures.

[0051] Illustrated in FIG. 3 is a typical deposition arrangement for acold-spray magnet, wherein the sprayed material is directed through thesupersonic converging/diverging nozzle 22 is applied to an aluminumcarrier 24 at short (<2.5 cm) standoff distance from the nozzle end. Bymanipulating the carrier in its own plane or by manipulating separatelythe nozzle, it is possible to “draw” traces TF of any dimension. Thethickness of the deposit at any position is governed by the residencetime during which the spray is maintained at any given X-Y position ofthe substrate or nozzle. FIG. 3 shows a rectangular nozzle, which isoptimized for the cold-gas spray process, although it will beappreciated that other nozzle geometries or entire nozzle arrays may beconstructed to produce patterns as can be designed.

[0052] In addition to producing a basic permanent magnet, the inventionenables the production of electric machines such as motors, generators,alternators, solenoids and actuators. The basic method is thus describedin terms of a patternable arrangement of conductors, bulk material ofhard and soft magnetic materials on appropriate substrates forgeneration of electromagnetic elements.

[0053] Electric motors and generators are identical in terms ofmanufacturing and construction and differ mainly in their function,being often referred to commonly as “electric machines”. In some casesan electronic converter is used as an interface between the power supply(typically either the electrical power grid or a battery) and theelectric machine. It is often the configuration of this conversiondevice that determines whether the electric machine in question willoperate as a motor, a generator (“alternator” in most automotiveapplications) or both.

[0054] An electric machine is typically composed of two types ofelements, that can be arbitrarily placed on the rotating element (the“rotor”) or the stationary element (the “stator”). These two elementsconstitute a field-producing element called the “excitation” and atorque-producing element called the “armature”. The latter is mosttypically a polyphase winding, comprised of several coils properlyconnected. The “excitation” can be provided by a coil, a multiplicity ofcoils or by a permanent magnet array.

[0055] Illustrated in FIG. 4 is an electrical coil 32 made using thesame cold-spray process described. A copper electrical contact 34 isdeposited as the bulk-material. This construction may be used tofabricate the coil portion of the motor.

[0056] Illustrated in FIG. 5 is a cross-sectional view of aspray-deposited permanent magnet array 36 and a planer coil 38 producedby the method described above. If the coil 38 is integrally assembledwith the moving element or “rotor”, then the electrical EMF must beextracted through some type of mechanical commutator arrangement whichis well-known in the art (e.g., DC motor/generator). Alternatively, themoving permanent magnet array can be envisioned with a stationary coilset obviating the need for a commutator (e.g., brushless permanentmagnet motor/generator). It will be apparent that integral permanentmagnets developed by a simple spray process could be incorporated intovarious moving features of the motor with planar coils arrangedadjacently to extract electrical power as required, or to produceresultant forces which could act as a braking or accelerating elements.

[0057] The motor 40 is made from a support 42 secured to the core 44.Depending on the physical requirements of the motor 40, the support 42may be eliminated. This is useful if the permanent magnets 36 aredirectly applied to a motor component such as the motor housing or therotor. The core 44 may be optimized to conduct the magnetic flux 50.Materials such as cast iron and steel are suitable conduits for themagnetic flux between the permanent magnets 36. Assemblies can beproduced that take advantage of magnetically-soft, rotating articles ina vehicle, such as the engine flywheel, to act as the carrier. Thecarrier 44 directs the magnetic flux 50 between adjacent magnets 36,where the magnetic flux lines penetrate the area defined by the coil 38are enhanced by the underlying soft magnetic material of the carrier.Electrical insulation 46 between the coil 38 and the armature core 48isolates the coil 38. from the armature core 48. It will also beapparent that the magnetic flux 50 penetrating the area defined by thecoil 38, can also be greatly enhanced through a symmetric arrangement ofmagnets on either side of the coil 38. The concentration of magneticflux lines by the judicious arrangement of soft magnetic elements willincrease the effective power density of an electric machine employingthis construction.

[0058] In some cases both field and armature functions are combined intoa single stationary winding and the rotating element is shaped in orderto create a saliency in the magnetic circuit (e.g., synchronousreluctance and switched reluctance machines). The saliency provides apreferred path for the magnetic flux to flow and creates the opportunityto generate reluctance torque. This type of machine is often consideredthe simpler to build, since the rotating element is a single medium,passive device.

[0059] High-velocity, cold spray deposition processes provide a means toproduce electromagnetic design elements in robust, planarized form oninert substrates such as metals with insulating coatings, ceramics orpolymers. Such devices can allow for simple motors and generators oralternators to be fabricated on the surfaces of other devices, or asfree-standing appliances. Planarized starter/alternators for examplecould be envisioned that offer unique packaging opportunities.Alternatively, one could imagine miniature “generators” built intobraking system surfaces for regenerative energy recovery. By effectively“printing” these devices using cold spray depositions, the manufacturingcosts could be reduced from current means while also being adapted tothe mechanical systems at hand.

[0060] The invention has been described as a method of fabricatingpermanent magnets, soft magnetics and electrical conductors in the formof patterned deposits on supporting structures. While the best modes forcarrying out the invention have been described in detail, those familiarwith the art to which this invention relates will recognize variousalternative designs and embodiments for practicing the invention asdefined by the following claims.

1. A method of producing a permanent magnet comprising the steps of:kinetically spraying an admixture of a magnetic material and a bindermaterial, the kinetic spraying occurring at a temperature substantiallybelow the melting temperature of the magnetic material, said kineticallysprayed admixture forming a solid permanent magnet.
 2. The method ofclaim 1, further comprising the step of kinetically spraying saidadmixture atop a carrier, and said admixture adhering to said carrier.3. The method of claim 1, further comprising the step of applying amagnetic field to said kinetically sprayed admixture to create apermanent magnetic moment within said kinetically sprayed admixture. 4.The method of claim 2, wherein said admixture includes powdered magneticmaterial and powdered binder material and said kinetic spraying causessaid powered magnetic and binder material to be propelled against saidcarrier.
 5. The method of claim 4, wherein said propelled powderedmagnetic and binder materials are ductile and from a solid bulk atopsaid carrier.
 6. The method of claim 5, wherein said solid bulk ismetallurgically and mechanically bonded to said carrier.
 7. The methodof claim 1, wherein said magnetic material is selected from the groupconsisting of iron, nickel, cobalt, samarium-cobalt,aluminum-nickel-cobalt, neodymium-iron-boron and samarium-iron-nickel ormixtures thereof.
 8. The method of claim 1, wherein said binder materialis selected from the group consisting of iron, nickel or cobalt ormixtures thereof.
 9. The method of claim 2, wherein said carrier isaluminum.
 10. The method of claim 2, wherein said carrier is iron. 11.The method of claim 1, wherein said admixture has a particle size ofless than 325 mesh.
 12. The method of claim 1, further comprisingspraying said admixture with a carrier gas having a temperature between325-360° C.
 13. The method of claim 1, wherein the volume fraction ofbinder material is between 10 and 80% by weight of said permanentmagnet.
 14. The method of claim 1, wherein said binder material isparticles having a coating resistant to eddy current flow betweenadjacent particles.
 15. The method of claim 14, wherein said eddycurrent resistant coating is a selected from the group comprising oxide,organic or polymeric films.
 16. A method of producing a permanent magnetcomprising the steps of: preparing an admixture of magnetic material andbinder material, said admixture having a particle size less than 325mesh; heating a carrier gas to a temperature substantially below themelting point of either component of said admixture; introducing saidadmixture into said carrier gas; spraying said admixture atop a ductilecarrier, said admixture adhering to said carrier; forming a solidpermanent magnet; and applying an electric field to said magnet tocreate a permanent magnetic moment.
 17. The method of claim 16, whereinsaid magnetic material is selected from the group consisting of iron,nickel, cobalt, samarium-cobalt, aluminum-nickel-cobalt,neodymium-iron-boron and samarium-iron-nickel or mixtures thereof. 19.The method of claim 17, wherein said binder material is selected fromthe group consisting of iron, nickel or cobalt or mixtures thereof. 20.The method of claim 16, wherein said carrier is aluminum.
 21. The methodof claim 16, wherein said carrier is iron.
 22. A method of producing apermanent magnet attached to a component of an electric machinecomprising the steps of: preparing an admixture of magnetic material andbinder material; heating a carrier gas to a temperature substantiallybelow the melting point of either component of said admixture;introducing said admixture into said carrier gas; spraying saidadmixture atop said component, said admixture adhering to saidcomponent; forming a solid permanent magnet adhered to said component;applying an electric field to said magnet to create a permanent magneticmoment.
 22. The method of claim 21, wherein said admixture of magneticmaterial and binder material have a particle size less than 325 mesh.23. The method of claim 21, wherein said magnetic material is selectedfrom the group consisting of iron, nickel, cobalt, samarium-cobalt,aluminum-nickel-cobalt, neodymium-iron-boron and samarium-iron-nickel ormixtures thereof.
 24. The method of claim 21, wherein said bindermaterial is selected from the group consisting of iron, nickel or cobaltor mixtures thereof.
 25. The method of claim 21, wherein said carrier isaluminum.
 26. The method of claim 21, wherein said carrier is iron. 27.The method of claim 21, wherein said electric machine is a motor. 28.The method of claim 21, wherein said electric machine is a generator.29. The method of claim 21, further comprising the step of kineticallyspraying a conductor coil atop a second component of said machine. 30.The method of claim 29, further comprising the step of aligning saidcomponent and said second component whereby said magnetic momentpenetrates the coil.
 31. An electric machine comprising: a kineticallysprayed permanent magnet material and a binder material forming acomposite admixture having microstructures of permanent magnet materialembedded in the binder material, said admixture having a permanentmagnetic moment.
 32. The electric machine of claim 31, wherein saidadmixture of magnetic material and binder material has a particle sizeless than 325 mesh.
 33. The electric machine of claim 31, wherein saidmagnetic material is selected from the group consisting of iron, nickel,cobalt, samarium-cobalt, aluminum-nickel-cobalt, neodymium-iron-boronand samarium-iron-nickel or mixtures thereof.
 34. The electric machineof claim 31, wherein said binder material is selected from the groupconsisting of iron, nickel or cobalt or mixtures thereof.
 35. Theelectric machine of claim 32, wherein said component is aluminum. 36.The electric machine of claim 31, wherein said carrier is iron.
 37. Theelectric machine of claim 31, wherein said electric machine is a motor.38. The electric machine of claim 31, wherein said electric machine is agenerator.
 39. The electric machine of claim 31, further comprising akinetically sprayed conductor coil attached to a second component. 40.The electric machine of claim 31, wherein said second component isaligned with said first component whereby a magnetic moment penetratesthe coil.
 41. A method of manufacturing electric machines comprising thesteps of: kinetically spraying a powdered admixture of magnetic materialand ductile binder material on to a substrate; applying a concentratedmagnetic field to said sprayed admixture to cause said sprayed admixtureto cause magnetic dipole alignment in said sprayed admixture.
 42. Themethod of claim 41, wherein said binder material is selected from thegroup comprising iron, nickel, cobalt or alloys thereof.
 43. The methodof claim 41, wherein said magnetic material is selected from comprisingiron, nickel, cobalt, samarium-cobalt (SmCo₅, Sm₂Co₁₇), AlNiCo,Neodymium Iron Boron (Fe₁₄Nd₂B), Samarium Iron Nickel (SmFeNi).
 44. Themethod of claim 41 wherein the ductile binder material is magneticparticles individually coated with eddy current resistant films.
 45. Themethod of claim 44, wherein the films are selected from the groupcomprising oxide films, organic films and polymeric films.
 46. Themethod of claim 41 wherein the substrate accepting the permanent magnetsprayed admixture is a soft magnetic material that internally directsmagnet flux.